Generac Power Systems 9797-3 User manual

Brand: Generac Power Systems

Model: 9797-3

Category: Power generators

Type: User manual

This manual is also suitable for

5500EXL

Problems?

Questions?

Before taking your unit

back to the store,

call the generator

helpline at

1-800-270-1408

M-F 8-5 CT

Portable Generator Owner’s Manual

DANGER! This generator is designed for outdoor use only. Never use this generator inside any building

or enclosure including the generator compartment of a recreational vehicle (RV). Carbon monoxide

poisoning, fire and/or an explosion may result. No user performed modifications, including venting of

exhaust and/or cooling ventilation, will eliminate the danger. Always have at least two feet of clearance on

all sides of the generator even while operating the unit outdoors.

DANGER! You must isolate the generator from the electric utility by opening the electrical systems main

circuit breaker or main switch if this unit is used for backup power. Failure to isolate the generator from

the power utility may result in injury or death to electric utility workers and damage to the

generator due to a backfeed of electrical energy.

The Emission Control System for this generator is warranted for standards set by the

Environmental Protection Agency. For warranty information refer to the engine owners manual.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

5500EXL

GENERAC

The Reliable Ones

Model No. 9797-3 (5500 Watt AC Generator) Manual No. 20820 Revision 3 (2/17/2000)

Visit our Generac website: www.generac-portables.com

Generac Portable Products 5500EXL Extended Life Generator

EQUIPMENT DESCRIPTION

This generator is an engine-driven, revolving field,

alternating current (AC) generator. It was designed to

supply electrical power for operating compatible

electrical lighting, appliance, tool and motor loads.

This manual contains information for a generator that

operates 120 and/or 240 Volt AC, single phase, 60Hz

devices that require up to 5,500 watts (5.5 kW) of

power that pull up to 45.8 Amps at 120 Volts or

22.9 Amps at 240 Volts.

CAUTION: Do Not exceed the generators

wattage/amperage capacity. Add up the rated

watts of all devices you will connect to

generator receptacles at one time. This total

should not be greater than 5,500 watts for this

generator. Review Dont Overload the

Generator on page 11.

The generators revolving field is driven at about

3600 rpm by a single-cylinder engine.

Every effort has been made to ensure that information

in this manual is accurate and current. However,

Generac reserves the right to change, alter or

otherwise improve the product and this document at

any time without prior notice.

DANGER: Do Not tamper with engine

governed speed. High operating speeds are

dangerous and increase the risk of personal

injury or damage to equipment. The unit

supplies correctly rated frequency and voltage

only when running at proper governed speed.

Incorrect frequency and/or voltage can damage

some connected electrical loads. Operating at

excessively low speeds imposes a heavy load

on the engine, and may shorten engine life.

SAFETY RULES

This generator set was designed and manufactured for

specific applications. Do Not attempt to modify the unit

or use it for any application it was not designed for. If

you have any questions about your generators

application, ask your dealer or consult the factory.

The manufacturer could not possibly anticipate every

circumstance that might involve a hazard. For that

reason, warnings in the manual and warnings on tags

or decals affixed to the unit are not all-inclusive. If you

intend to handle, operate or service this unit by a

procedure or method not specifically recommended by

the manufacturer, first make sure the procedure or

method will not render this equipment unsafe or pose a

threat to you and others.

Read this manual carefully and become familiar

with your generator set. Know its applications, its

limitations and any hazards involved.

 The generator produces a very powerful voltage that

can cause extremely dangerous electrical shock.

Avoid contact with bare wires, terminals, etc. Never

permit any unqualified person to operate or service

the generator.

 Never handle any kind of electrical cord or device

while standing in water, while barefoot or while

hands or feet are wet.

 The National Electric Code requires the frame and

external electrically conductive parts of the unit to be

properly connected to an approved earth ground.

Local electrical codes may also require proper

grounding of the generator. Consult with a local

electrician for requirements in your area.

 Use a ground fault circuit interrupter in any damp or

highly conductive area (such as metal decking or

steel work).

The engine exhaust from this product contains

chemicals known to the State of California to

cause cancer, birth defects, or other

reproductive harm.

WARNING:

Generac Portable Products 5500EXL Extended Life Generator

 Do Not use worn, bare, frayed or otherwise

damaged electrical cord sets with the generator.

 Operate the generator only on level surfaces and

where it will not be exposed to excessive moisture,

dirt, dust or corrosive vapors.

 Gasoline is highly FLAMMABLE and its vapors are

EXPLOSIVE. Do Not permit smoking, open flames,

sparks or heat in the vicinity while handling gasoline.

Avoid spilling gasoline on a hot engine. Comply with

all regulations requiring storage and handling of

gasoline.

 Do Not overfill the fuel tank. If overfilled, fuel can

contact the hot engine and cause FIRE or an

EXPLOSION.

 Never store the generator with fuel in its tank where

gasoline vapors might reach an open flame, spark or

pilot light (as on a furnace, water heater or clothes

dryer). FIRE or EXPLOSION might result.

 Generator exhaust gases contain DEADLY carbon

monoxide gas. This dangerous gas, if breathed in

sufficient concentrations, can cause

unconsciousness or even death. Operate this

equipment only in the open air where adequate

ventilation is available.

 The unit requires an adequate flow of cooling air for

its continued proper operation. Never operate the

unit inside any room or enclosure where the free flow

of cooling air into and out of the unit might be

obstructed. Without sufficient cooling air flow, the unit

quickly overheats, damaging the generator or nearby

property.

 Allow at least 2 feet of clearance on all sides of the

generator or you could damage the unit. Review

Cold Weather Operation on page 8.

 Never start or stop the unit with electrical loads

connected to receptacles AND with the connected

devices turned ON. Start the engine and let it

stabilize before connecting electrical loads.

Disconnect all electrical loads before shutting the

unit down.

 Do Not insert any object through the units cooling

slots. You could damage the unit or injure yourself.

 Never operate this generator:

in rain; in any enclosed compartment; when

connected electrical devices overheat; if electrical

output is lost; if engine or generator sparks; if flame

or smoke is observed while running; if unit vibrates

excessively.

GROUNDING THE

GENERATOR

The National Electric Code requires the frame and

external electrically conductive parts of generator be

properly connected to approved earth ground.

Local electrical codes may also require proper

grounding of this unit. For that purpose, a

GROUNDING WING NUT (Figure 1) is provided on the

frame of your unit.

Generally, connecting a No. 12 AWG (American Wire

Gauge) stranded copper wire to the grounding wing

nut and to an earth-driven copper or brass grounding

rod (electrode) provides adequate protection against

electrical shock.

However, local codes may vary widely. Consult with a

local electrician for grounding requirements in your

area. Be sure to keep the ground wire attached while

you connect the electrode.

Properly grounding the generator helps prevent

electrical shock if a ground fault condition exists in the

generator or in connected electrical devices. Proper

grounding also helps to dissipate the static electricity

which may build up in ungrounded devices.

Figure 1  Location of Grounding Wing Nut

Grounding Wing Nut

120/240 Volt AC

30 Amp Receptacle

Generac Portable Products 5500EXL Extended Life Generator

KNOW YOUR GENERATOR

Read this owners manual and safety rules before operating your generator.

Compare the illustrations with your generator to familiarize yourself with the locations of various controls and

adjustments. Save this manual for future reference.

12 Volt DC, 10 Amp Receptacle  Used with battery

charge cables to charge a 12 Volt battery.

120 Volt AC, 20 Amp Receptacles  May be used to

supply electrical power for the operation of 120 Volt

AC, single phase, 60 Hz electrical lighting, appliance,

tool and motor loads.

120 Volt AC, 30 Amp Receptacle  May be used to

supply electrical power for the operation of 120 Volt

AC, 30 Amp, single phase, 60 Hz electrical lighting,

appliance, tool and motor loads.

120/240 Volt AC, 30 Amp Receptacle  May be used

to supply electrical power for the operation of 120

and/or 240 Volt AC, 30 Amp, single phase, 60 Hz

electrical lighting, appliance, tool and motor loads.

Battery Tray Location  Pre-tapped and installed

screws are found here for the battery tray

Circuit Breakers (AC)  Each receptacle is provided

with a "push to reset" circuit breaker to protect the

generator against electrical overload.

Electric Start Button  Press to start unit.

Fuel Tank  Capacity of seven U.S. gallons of

unleaded fuel.

Grounding Wing Nut Use this connection to

properly ground the generator.

Idle Control Switch  The idle control runs the

engine at normal (high) speeds when there is a load

present and runs the engine at idle (low) speeds when

a load is not present.

Recoil Starter  Used as an alternate method of

starting the unit.

120 Volt AC, 20 Amp

Receptacle

Idle Control Switch

Recoil Starter

Electric Start Button

Battery Tray

Location

120 Volt AC, 30 Amp

Receptacle

Circuit Breakers (AC)

12 Volt DC, 10 Amp

Receptacle

Grounding Wing Nut

Fuel Tank

Generac Portable Products 5500EXL Extended Life Generator

Your generator requires some assembly and is ready

for use after it has been properly serviced with the

recommended oil and fuel.

If you have any problems with the assembly of

your generator, please call the generator helpline

at 1-800-270-1408.

IMPORTANT: Any attempt to run the unit before it has

been serviced with the recommended oil will result in

an engine failure.

REMOVE GENERATOR

FROM CARTON

 Set the carton on a rigid flat surface with This Side

Up arrows pointing upward.

 Carefully open the top flaps of the shipping carton

(review Cold Weather Operation on page 8).

 Cut down corners at one end of carton from top to

bottom and lay that side of carton down flat.

 Remove all packing material, carton fillers, etc.

 Remove the generator from the shipping carton.

CARTON CONTENTS

Check all contents. If any parts are missing or

damaged, call the generator helpline at

1-800-270-1408.

 The generator

 Electric start battery cables

 Generator and engine owners manuals

 Locking 20 Amp and 30 Amp plugs

 Battery charge cables

 Battery tray mounting bracket/hardware

 Spare spark plug and air filter element

 Spark plug wrench

INSTALLING TRAY AND

BATTERY

You must purchase and install a 12 Volt DC battery

(Series U1-109). The battery should be serviced with

electrolyte fluid and fully charged prior to installation.

Install the battery as follows:

 Find battery tray and fasteners (loose) in carton.

Includes all parts needed to mount battery and tray.

 Remove the 4 battery tray screws from cradle.

 Position the battery tray and install (Figure 2).

 Set battery onto tray (Figure 3).

Figure 3  Install Battery onto Battery Tray

Figure 2  Install Battery Tray

Generac Portable Products 5500EXL Extended Life Generator

 Retain battery to tray with 2 J-bolts, 2 lock washers

and 2 hex nuts (Figure 3).

 Connect the red battery cable from the engine start

button to the positive (+) terminal on battery

(Figure 4).

 Connect the black battery cable to the negative ()

terminal on battery (Figure 4).

 Connect the other end of the black cable to the

engine mount, not the frame.

CAUTION: Be sure the black cable is

connected to the engine mount, not the frame.

You could damage the ground wire.

BEFORE STARTING THE

ENGINE

Perform the following tasks before starting the unit:

Add Oil

WARNING! Any attempt to crank or start the

engine before it has been properly filled with the

recommended oil may result in an engine

failure.

To fill your engine with oil:

 Place generator on a level surface.

 Follow the oil grade recommendations and oil fill

instructions given in the engine owners manual.

NOTE: The generators revolving field rides on a

prelubricated and sealed ball bearing that requires no

additional lubrication for the life of the bearing.

Add Fuel

DANGER: NEVER fill fuel tank indoors.

NEVER fill fuel tank when engine is running or

hot. Do Not light a cigarette or smoke when

filling the fuel tank.

CAUTION: Do Not overfill the fuel tank.

Always allow room for fuel expansion.

Use only regular UNLEADED gasoline.

IMPORTANT: It is important to prevent gum deposits

from forming in essential fuel system parts such as the

carburetor, fuel filter, fuel hose or tank during storage.

Also, experience indicates that alcohol-blended fuels

(gasohol, ethanol or methanol) attract moisture,

leading to separation and formation of acids during

storage. Acidic gas can damage the fuel system of an

engine.

Figure 4  Connect Battery Cables

RED wire from

Start Button

BLACK wire from

engine mount

Generac Portable Products 5500EXL Extended Life Generator

To avoid engine problems, the fuel system should be

emptied before storage of 30 days or longer. Drain the

gas tank, start engine and let it run until the fuel lines

and carburetor are empty. Use fresh fuel next season.

See Storage on page 12.

Never use engine or carburetor cleaner products in the

fuel tank or permanent damage may occur.

To add fuel:

 Clean area around fuel fill cap, remove cap.

 Slowly add UNLEADED regular gasoline to fuel

tank. Leave about a 1/2" space in the fuel tank for

fuel expansion (Figure 5). Do Not overfill fuel tank.

 Install fuel cap and wipe up any spilled gasoline.

OPERATING THE

GENERATOR

CAUTION! Never start or stop unit with

electrical loads connected AND with the

connected devices turned ON.

Starting the Engine

 Disconnect all electrical loads from the generator.

 Open the fuel shut-off valve (Figure 6).

 Set the Run/Stop switch to Run position.

 Make sure the Idle Control switch is in Off position.

 Move engine choke to Full choke position

(Figure 7).

For electric start:

 Press electric start button until engine cranks and

starts.

For manual start:

 Pull slowly on recoil handle until you feel some

resistance. Then pull rapidly to start engine. Return

recoil slowly, Do Not let it snap back.

Figure 7  Choke Positions

Figure 5  Fuel Tank Air Space

Figure 6  Fuel Shut Off Valve

Generac Portable Products 5500EXL Extended Life Generator

 When engine starts, move choke lever to

Half choke position until the engine runs smoothly

and then to Run position. If engine falters, move

choke lever to Half choke position until the engine

runs smoothly and then to Run position.

NOTE: If engine fails to start after 3 pulls, move the

choke lever to Run position and pull starter rope

again.

NOTE: If engine still fails to start after 3 pulls, check for

proper oil level in crankcase. This unit is equipped with

a Low Oil Shutdown System. See engine manual.

NOTE: If engine fires, but does not continue to run,

move choke lever to Full choke position and repeat

starting instructions.

Refer to the engine owners manual for complete

starting instructions.

Applying Electrical Loads

 Let engine stabilize and warm up for about five

minutes after starting.

 Plug in and turn on the desired 120 or 240 Volt AC,

single phase, 60 Hz electrical loads.

DO NOT OVERLOAD THE GENERATOR. Review

Dont Overload the Generator on page 11.

Stopping the Engine

 Disconnect all electrical loads.

 Set the idle control to Off position.

 Run engine at no-load for about two minutes.

 Place the the Run/Stop switch to Stop.

 Close the fuel shutoff valve.

Operating Automatic Idle Control

This switch is designed to greatly improve fuel

economy. When this switch is turned ON, the engine

will only run at its normal high engine speed when an

electrical load is connected. When the electrical load is

removed, the engine will run at a reduced speed. With

the switch OFF, the engine will run constantly at the

normal high engine speed. Always have the switch

OFF when starting and stopping the engine.

COLD WEATHER

OPERATION

Under certain weather conditions (temperatures below

40°F [4°C] and a high dew point), your generator may

experience icing of the carburetor and/or the

crankcase breather system. In an emergency, use the

original shipping box as a temporary shelter:

 Cut off all flaps and one of the long sides of the box

to expose exhaust side of unit. Cut appropriate slots

to access units receptacles.

 Start unit, then place box over it. Ensure a minimum

of two feet clearance between open side of box and

nearest object.

IMPORTANT!: Remove shelter when temperature is

above 40°F [4°C].

For a more permanent shelter, build a structure that

will enclose three sides and the top of the generator.

Make sure entire muffler-side of generator is exposed,

with two feet clearance between open side of box and

nearest object. Face exposed end away from wind and

elements (Figure 8).

Figure 8  Temporary Cold Weather Shelter

Wind

Charging a Battery

DANGER: Storage batteries give off explosive

hydrogen gas while recharging. An explosive

mixture will remain around the battery for a long

time after it has been charged. The slightest

spark can ignite the hydrogen and cause an

explosion. Such an explosion can shatter the

battery and cause blindness or other injury.

DANGER: Do Not permit smoking, open

flame, sparks or any other source of heat

around a battery. Wear protective goggles,

rubber apron and rubber gloves when working

around a battery. Battery electrolyte fluid is an

extremely caustic sulfuric acid solution that can

cause severe burns. If spill occurs, flush area

with clear water immediately.

Your generator has the capability of recharging a

discharged 12 Volt automotive or utility style storage

battery. Do Not use the unit to charge any 6 Volt

batteries. Do Not use the unit to crank an engine

having a discharged battery.

To recharge 12 Volt batteries, proceed as follows:

 Check fluid level in all battery cells. If necessary, add

ONLY distilled water to cover separators in battery

cells. Do Not use tap water.

 If the battery is equipped with vent caps, make sure

they are installed and are tight.

 If necessary, clean battery terminals.

 Connect battery charge cable connector plug to

panel receptacle identified by the words

12-VOLT D.C..

 Connect battery charge cable clamp with red handle

to the positive (+) battery terminal (Figure 9).

 Connect battery charge cable clamp with black

handle to the negative () battery terminal

(Figure 9).

 Start engine. Let the engine run while battery

recharges.

 When battery has charged, shut down engine.

NOTE: Use an automotive hydrometer to test battery

state of charge and condition. Follow the hydrometer

manufacturers instructions carefully. Generally, a

battery is considered to be at 100% state of charge

when specific gravity of its fluid (as measured by

hydrometer) is 1.260 or higher.

Generac Portable Products 5500EXL Extended Life Generator

Figure 9  Battery Charge Cable Connection

Red

Black

Generac Portable Products 5500EXL Extended Life Generator

CORD SETS/RECEPTACLES

This generator is equipped with the following

receptacles:

120 Volt AC, 20 Amp Receptacles

Each socket (Figure 10) is protected against overload

by a 20 Amp push-to-reset circuit breaker. Use each

receptacle to operate 120 Volt AC, single phase, 60 Hz

electrical loads requiring up to 2400 watts (2.4 kW) at

20 Amps of current.

Use cord sets that are rated for 125 Volt AC loads at

20 Amps (or greater).

120 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L5-30 plug with this receptacle. Connect

a 3-wire cord set rated for 125 Volts AC at 30 Amps to

the plug (Figure 11).

Use this receptacle to operate 120 Volt AC, 60 Hz,

single phase loads requiring up to 3600 watts (3.6 kW)

of power at 30 Amps. The outlet is protected by a

30 Amp push-to-reset circuit breaker.

120/240 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L14-30 plug with this receptacle. Connect

a 4-wire cord set rated for 250 Volt AC loads at

30 Amps (or greater) (Figure 12). You can use the

same 4-wire cord if you plan to run a 120 Volt load.

This receptacle powers 120/240 Volt AC, 60 Hz, single

phase loads requiring up to 3,600 watts of power

(3.6 kW) at 30 Amps for 120 Volts OR 5,500 watts of

power (5.5 kW) at 22.9 Amps for 240 Volts. The outlet

is protected by a 30 Amp push-to-reset circuit breaker.

CAUTION! Although this outlet states it has a

240 Volt 30 Amp rating (up to 7,200 watts), the

generator is only rated for 5,500 watts.

Powering loads that exceed the wattage/

amperage capacity of the generator can

damage it or cause serious injuries.

240 Volt loads powered through this outlet

should not exceed 22.9 Amps of current draw.

Figure 12  120/240 Volt AC, 30 Amp Receptacle

Figure 11  120 Volt, 30 Amp Receptacle

Figure 10  120 Volt AC, 20 Amp Receptacles

Generac Portable Products 5500EXL Extended Life Generator

DONT OVERLOAD THE

GENERATOR

Overloading a generator in excess of its rated wattage

capacity can result in damage to the generator and/or

connected electrical devices. Observe the following, to

prevent overloading the unit:

 Add up the total wattage of all electrical devices to

be connected at one time. This total should NOT be

greater than the generators wattage capacity.

 If the appliance, tool or motor does not give wattage,

multiply 120 Volts times ampere rating to determine

watts (volts x amps = watts).

 The rated wattage of lights can be taken from

wattage listed on the light bulbs. The rated wattage

of tools, appliances and motors can usually be found

on a data plate or decal affixed to the device. Use

Figure 13 below as a general reference.

 Some electric motors, such as induction types,

require about three times more watts of power for

starting than for running. This surge of power lasts

for only a few seconds when starting such motors.

Be sure you allow for this high starting wattage

when selecting electrical devices to connect to your

generator. First figure the watts needed to start the

largest motor. Add to that figure the running watts of

all other connected loads.

Device . . . . . . . . . . . . . . . . . . . . . . . . . . Load (watts)

*Air Conditioner (12,000 Btu). . . . . . . . . . . . . . . . 1700

*Air Conditioner (24,000 Btu). . . . . . . . . . . . . . . . 3800

*Air Conditioner (40,000 Btu). . . . . . . . . . . . . . . . 6000

Battery Charger (20 Amp) . . . . . . . . . . . . . . . . . . . 500

Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . 1000

Chain Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200

Circular Saw (6-1/2") . . . . . . . . . . . . . . . . 800 to 1000

*Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . 5750

*Clothes Dryer (Gas) . . . . . . . . . . . . . . . . . . . . . . . 700

*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . 1150

Coffee Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750

*Compressor (1 HP) . . . . . . . . . . . . . . . . . . . . . . 2000

*Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . . 1800

*Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . . 1400

Curling Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700

*Freezer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700

*Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650

Disc Sander (9") . . . . . . . . . . . . . . . . . . . . . . . . . 1200

Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

Electric Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . 1200

Electric Range (per element). . . . . . . . . . . . . . . . 1500

Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250

*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . 875

*Garage Door Opener . . . . . . . . . . . . . . . . 500 to 750

Hair Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200

Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . 250 to 1100

Device . . . . . . . . . . . . . . . . . . . . . . . . . . Load (watts)

Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . 450

Impact Wrench. . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200

*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800

Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200

Light Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Microwave Oven. . . . . . . . . . . . . . . . . . . . 700 to 1000

*Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100

Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . 300

Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . 400

Oil Fired Space Heater (85,000 Btu) . . . . . . . . . . . 225

Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . 150

*Paint Sprayer, Airless (1/3 HP). . . . . . . . . . . . . . . 600

Paint Sprayer, Airless (handheld) . . . . . . . . . . . . . 150

Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 200

*Refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700

Slow Cooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

*Submersible Pump (1-1/2 HP) . . . . . . . . . . . . . . 2800

*Submersible Pump (1 HP) . . . . . . . . . . . . . . . . . 2000

*Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . 1500

*Sump Pump . . . . . . . . . . . . . . . . . . . . . . 800 to 1050

*Table Saw (10"). . . . . . . . . . . . . . . . . . . 1750 to 2000

Television . . . . . . . . . . . . . . . . . . . . . . . . . . 200 to 500

Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 to 1650

Weed Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

* Allow 3 times the listed watts for starting these devices.

Figure 13  Wattage Reference Guide

Generac Portable Products 5500EXL Extended Life Generator

GENERAL MAINTENANCE

RECOMMENDATIONS

The owner/operator is responsible for making sure that

all periodic maintenance tasks are completed on a

timely basis; that all discrepancies are corrected; and

that the unit is kept clean and properly stored. Never

operate a damaged or defective generator.

Engine Maintenance

See engine manual for instructions.

Generator Maintenance

Generator maintenance consists of keeping the unit

clean and dry. Operate and store the unit in a clean dry

environment where it will not be exposed to excessive

dust, dirt, moisture or any corrosive vapors. Cooling air

slots in the generator must not become clogged with

snow, leaves or any other foreign material.

Check the cleanliness of the generator frequently and

clean when dust, dirt, oil, moisture or other foreign

substances are visible on its exterior surface.

NOTE: Do Not use a garden hose to clean generator.

Water can enter engine fuel system and cause

problems. In addition, if water enters generator through

cooling air slots, some of the water will be retained in

voids and cracks of the rotor and stator winding

insulation. Water and dirt buildup on the generator

internal windings will eventually decrease the

insulation resistance of these windings.

Clean the Generator

 Use a damp cloth or soft bristle brush to wipe

exterior surfaces clean.

 A vacuum cleaner may be used to pick up loose dirt

and debris.

 Low pressure air (not to exceed 25 psi) may be used

to blow away dirt. Inspect cooling air slots and

opening on generator. These openings must be kept

clean and unobstructed.

SERVICE/ADJUSTMENTS

Refer to engine owners manual for information.

STORAGE

The generator should be started at least once every

seven days and allowed to run at least 30 minutes.

If this cannot be done and you must store the unit for

more than 30 days, use the following guidelines to

prepare it for storage.

Generator Storage

 Clean the generator as outlined in To Clean the

Generator.

 Check that cooling air slots and openings on

generator are open and unobstructed.

 Disconnect the negative battery cable from the

battery.

DANGER: Storage covers can be flammable.

Do Not place a storage cover over a hot

generator. Let the unit cool for a sufficient time

before placing the cover on the unit.

Engine Storage

See engine owners manual for instructions on how to

properly store the engine.

Other Storage Tips

 Do Not store gasoline from one season to another.

 Replace your gasoline can if it starts to rust. Rust

and/or dirt in a gasoline can cause problems when

you use contaminated fuel with this unit.

 Store in clean and dry area.

SPECIFICATIONS

Rated Maximum Continuous

AC Power Output. . . . . . . . . . . . 5500 watts (5.5 kW)

Rated AC Voltage . . . . . . . . . . . 120/240 Volts

Rated Maximum AC Current:

at 240 Volts. . . . . . . . . . . . . . . 22.9 Amperes

at 120 Volts. . . . . . . . . . . . . . . 45.8 Amperes

Phase . . . . . . . . . . . . . . . . . . . . 1

Rated AC Frequency. . . . . . . . . 60 Hertz

Number of Rotor Poles . . . . . . . 2

Driven Speed of Rotor . . . . . . . . 3600 RPM

Generac Portable Products 5500EXL Extended Life Generator

TROUBLESHOOTING

Problem Cause Correction

Engine is running, but no

AC output is available.

1. One of the circuit breakers is

open.

2. Fault in generator.

3. Poor connection or defective

cord set.

4. Connected device is bad.

1. Reset circuit breaker.

2. Contact Generac service facility.

3. Check and repair.

4. Connect another device that is in

good condition.

Engine runs good at no-load

but bogs down" when

loads are connected.

1. Short circuit in a connected load.

2. Engine speed is too slow.

3. Generator is overloaded.

4. Shorted generator circuit.

1. Disconnect shorted electrical load.

2. Contact Generac service facility.

3. See Don't Overload the

Generator on page 11.

4. Contact Generac service facility.

Engine will not start; or

starts and runs rough.

1. Run/Stop Switch set to Stop.

2. Dirty air cleaner.

3. Out of gasoline.

4. Stale gasoline.

5. Spark plug wire not connected to

spark plug.

6. Bad spark plug.

7. Water in gasoline.

8. Overchoking.

9. Excessively rich fuel mixture.

10. Intake valve stuck open or

closed.

11. Engine has lost compression.

12. Failed battery.

1. Set switch to Run.

2. Clean or replace air cleaner.

3. Fill fuel tank.

4. Drain gas tank; fill with fresh fuel.

5. Connect wire to spark plug.

6. Replace spark plug.

7. Drain gas tank; fill with fresh fuel.

8. Open choke fully and crank

engine.

9. Contact Generac service facility.

10. Contact Generac service facility.

11. Contact Generac service facility.

12. Replace battery.

Engine shuts down during

operation.

1. Out of gasoline.

2. Low oil level.

1. Fill fuel tank.

2. Fill crankcase to proper level.

Engine lacks power.

1. Load is too high.

2. Dirty air filter.

1. See Don't Overload the

Generator on page 11.

2. Replace air filter.

Engine hunts or falters.

1. Choke is opened too soon.

2. Carburetor is running too rich or

too lean.

1. Move choke to halfway position

until engine runs smoothly.

2. Contact Generac service facility.

Generac Portable Products 5500EXL Extended Life Generator

SCHEMATIC DIAGRAM

Generac Portable Products 5500EXL Extended Life Generator

WIRING DIAGRAM

Generac Portable Products 5500EXL Extended Life Generator

EXPLODED VIEW

Generac Portable Products 5500EXL Extended Life Generator

PARTS LIST

Item Part # Qty. Description

1 A92432 1 CRADLE

2 A92531 1 SUPPORT, Engine

3 A92731 1 SUPPORT, Engine & Muffler

4 92247 1 HOUSING, Engine Adapter

5 92678G 1 ASSEMBLY, Rotor

6 94980A 1 ASSEMBLY, Stator

7 65791 1 BEARING

8 67451 1 WASHER, Special Flat - M8

9 22129 16 WASHER, Lock - M8

10 86307 4 HHMS, 5/16-24 x 3/4

11 28092 1 HHCS, 5/16-24 x 9-1/4

12 92609 2 MOUNT, Vibration

13 82857 4 MOUNT, Vibration

14 92532 1 BRACKET, Muffler

15 90239 1 GASKET, Muffler

16 66476 2 CAPSCREW, M6 - 1.0 x

12mm

17 A7433 1 MUFFLER

18 40976 2 SCREW, M8 - 1.25 x 20

19 83083 1 SCREEN, Spark Arrester

20 81917 1 PIN, Roll 4mm x 10

25 66825C 1 CARRIER, Rear Bearing

26 74908 4 TAPTITE, M5-0.8 x 10

27 86308A 4 BOLT, Stator M6-1 x 145mm

28 65795 2 RECTIFIER, Battery Charge

29 66849C 1 TAPTITE, M5-0.8 x 30

30 67022 1 GROMMET, Rubber

31 84132 1 ASSEMBLY, Power Regulator

32 66386 1 ASSEMBLY, Brush Holder

33 66849 2 TAPTITE, M5-0.8 x 16

34 B67025 1 COVER, Bearing Carrier

35 22769 1 WASHER, Shakeproof Int. #10

36 86494 1 SCREW, M6-1.0 x 16 Wing

37 86292 1 HHCS, - #10 Self Driller

38 77395 4 NUT, Flange Lock - M6

39 83465 4 GROMMET, Tank

40 57058 4 HHCS, M6-1.0 x 55

41 80270 1 VALVE, Tank

42 78299 1 BUSHING, Tank

43 B4363 1 CAP, with Gauge, Fuel

44 B1695 1 TANK, Fuel 7 Gal.

45 B92039 1 SHIELD, Heat

Item Part # Qty. Description

46 92665 1 INSULATION, #2-1/4" Thick

47 85000 1 CLIP, Insulation

48 14353621 1 WIRE, Ground

49 26850 2 LW, EXT, Shakeproof M6

51 92982 1 DECAL, Danger

52 96057 2 DECAL, Heat Shield

55 25244 12 NUT, 5/16-18 Hex

57 96058 1 DECAL, Control Panel

58 92630 1 ASSEMBLY, Control Box

59 NSP 1 ENGINE

60 22531 2 HHCS, 5/16-18 x 1-3/4"

61 22142 2 SCREW, 5/16-18 x 3/4"

62 77282 1 SWITCH, Starter

63 22287 2 SCREW, 1/4 - 20 x 3/4

64 22097 2 LOCKWASHER, M6

65 22127 2 NUT, 1/4 - 20 Hex

66 78289 1 BRACKET, Starter Switch

67 93826 1 DECAL, Start Instructions

68 B96068 1 SHIELD, Heat

69 56893 5 CRIMPTITE, 10-24 x 1/2

70 B2153 8 SCREW, #12 Self Drill

71 22473 4 WASHER, Flat M6

Parts Not Illustrated:

37806 1 125V 30A Locking plug

43438 1 240V 30A Locking plug

72347 1 Spark plug

73111 1 Air cleaner element

84882 1 Spark plug wrench

20820 1 Owners manual

65787 1 Battery charge cable

Battery Tray Components:

22129 2 Lockwasher, M8

45771 2 Hex nut M8

96925 1 Battery tiedown

96924 2 J-bolt

15453621 1 Battery cable, positive

15553621 1 Battery cable, negative

96923 1 Battery tray

22145 2 Flat washer

58443 4 Screws, battery tray

Generac Portable Products 5500EXL Extended Life Generator

Item Part # Qty. Description

1 A92070 1 PANEL, Control

2 23897 4 FLAT WASHER, #10 M5

3 49226 4 LOCK WASHER, M5

4 91526 4 SCREW, M5-0.8 x 12mm

5 82538 1 SWITCH, Idle Control

6 82881 4 LOCK WASHER, 7/16"

7 43181 4 SCREW, M3 - 0.5 x 10mm

8 43182 4 LOCK WASHER, M3

9 90418 1 OUTLET, 12V

10 75207A 2 CIRCUIT BREAKER, 30A

11 75207 2 CIRCUIT BREAKER, 20A

12 23365 6 WASHER, #8 Shakeproof

13 68868 1 OUTLET, 120 Volt, 30 Amp

Locking Type

Item Part # Qty. Description

14 43437 1 OUTLET, 120V/240V, 30A

Locking Type

15 68759 1 OUTLET, 120V, 20A Duplex

16 43180 6 FLAT WASHER, M4

17 22264 6 LOCK WASHER, #8 M4

18 51715 6 NUT, M4-0.7 Hex

19 64526 8 SCREW, #6-32 x 3/8"

20 83970 1 BOARD, System Control

21 64525 4 STAND-OFF, 3/4" Hex

22 87962 1 CIRCUIT BREAKER. 12V,

10A (auto)

23 84335 1 ASSEMBLY, Wire Harness

24 84134 1 GROMMET, Rubber Conn

25 B92069 1 BOX, Control Panel

26 84028 1 TRANSFORMER, Idle Control

CONTROL PANEL EXPLODED VIEW & PARTS LIST

Generac Portable Products 5500EXL Extended Life Generator

NOTES

LIMITED WARRANTY

FOR "GN" ENGINE DRIVEN PORTABLE GENERATORS

GENERAC PORTABLE PRODUCTS (hereafter referred to as the COMPANY) warrants to the original purchaser

that the alternator and control panel for its portable generator will be free from defects in materials or

workmanship for the items and period set forth below from the date of original purchase. This warranty is not

transferable and applies only to portable generators driven by a GN-Series engine.

Consumer* Commercial*

Alternator 2 years (2nd year parts only) 1 year

Engine Warranted solely by the engine manufacturer

With the exception of European Community Countries, all units bound for export shall be warranted for

One (1) Year in Consumer applications, and 90 days in Commercial applications as defined below.

*NOTE: For the purpose of this warranty "consumer use" means personal residential household use by

original purchaser. This warranty does not apply to units used for Prime Power in place of utility.

"Commercial Use" means all other uses, including rental, construction, commercial and income

producing purposes. Once a generator has experienced commercial use, it shall thereafter be considered

a commercial use generator for the purposes of this warranty.

During said warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination

by the COMPANY, is found to be defective under normal use and service**. Starting batteries are not warranted

by the COMPANY. All transportation costs under warranty, including return to the factory if necessary, are to be

borne by the purchaser and prepaid by the purchaser. This warranty does not cover normal maintenance and

service and does not apply to a generator set, alternator, or parts which have been subjected to improper or

unauthorized installation or alteration, misuse, negligence, accident, overloading, overspeeding, improper

maintenance, repair or storage so as, in the COMPANYs judgement, to adversely affect its performance and

reliability.

**NORMAL WEAR: As with all mechanical devices, the generator need periodic parts service and

replacement to perform well. This warranty will not cover repair when normal use has exhausted the life

of a part or generator.

THERE IS NO OTHER EXPRESS WARRANTY. THE COMPANY HEREBY DISCLAIMS ANY AND

ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY

AND FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE

DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO

THE TIME PERIOD AS SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR

CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES UNDER ANY AND ALL WARRANTIES

IS EXCLUDED. THE COMPANY ALSO DISCLAIMS ANY RESPONSIBILITY FOR INCIDENTAL OR

CONSEQUENTIAL DAMAGES, SUCH AS THE LOSS OF TIME OR THE USE OF THE POWER

EQUIPMENT, OR ANY COMMERCIAL LOSS DUE TO THE FAILURE OF THE EQUIPMENT: AND

ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN

WARRANTY.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of

incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty

gives you specific legal rights and you may also have other rights, which vary from state to state.

For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Warranty

service can be performed only by a COMPANY authorized service facility. This warranty will not apply to service

at any other facility. At the time of requesting warranty service, evidence of original purchase date must be

presented.

GENERAC PORTABLE PRODUCTS

Jefferson, Wisconsin 53549

Generac Power Systems 9797-3 User manual

Brand: Generac Power Systems

Model: 9797-3

Category: Power generators

Type: User manual

This manual is also suitable for

5500EXL

Download PDF

report

Generac Power Systems 9797-3 User manual

This manual is also suitable for

Generac Power Systems 9797-3 User manual

Related papers

Other documents